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Multi-Material to Space Fraunhofer Researchers Push 3D Printing for Rocket Engines

Source: Fraunhofer IGCV | Translated by AI 3 min Reading Time

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Rockets are expected to become increasingly application-flexible and also more cost-effective. An efficient lever can be applied in engine manufacturing. Namely through additive manufacturing ...

A view of a launching Ariane rocket and especially the bubbling engine system. Unfortunately, rocket developers feel compelled to face certain pressures. Once again, it's all about money! Researchers from Augsburg are therefore relying on 3D printing to help them ...(Image: ESA / CNES / Arianespace)
A view of a launching Ariane rocket and especially the bubbling engine system. Unfortunately, rocket developers feel compelled to face certain pressures. Once again, it's all about money! Researchers from Augsburg are therefore relying on 3D printing to help them ...
(Image: ESA / CNES / Arianespace)

As part of a large-scale EU research project, the Fraunhofer Institute for Foundry, Composite, and Processing Technology (IGCV) is currently developing innovative methods for the additive manufacturing of rocket components. The goal is to significantly reduce costs and development times, increase material efficiency, and make Europe's access to space more independent, according to researchers from Augsburg. The core of this development is the production of multi-material components using selective laser melting (SLM), as further reported.

Many Weeks Earlier to the Suitable Rocket Engine

In the additive manufacturing process, two or more powder materials—such as different metals or alloys—are simultaneously fused using the energy of a laser beam. This allows the production of components with varying material properties—for example, different hardness or corrosion resistance—in a single manufacturing process. With this production method, the components can also be directly adjusted on the computer and then immediately printed. The immense flexibility in design, for which 3D printing is generally known, saves lead times and allows for quick iterations when requirements change. The savings potential for rocket engine development is estimated by experts in terms of weeks.

A Printed Demonstrator Promises Success

Using this variant of 3D metal printing, the researchers at Augsburg's IGCV also produced a multi-material demonstrator for rockets. More specifically, a valve component was created from alternating magnetic and non-magnetic steel alloys. According to the scientists, it helps ensure that the rocket remains stably aligned during flight. The high density and precise material distribution demonstrated in the laboratory already confirm the required component performance, as emphasized. Now, the experts are directly comparing their 3D-printed prototype with conventionally milled and then welded versions to demonstrate functionality, efficiency, cost, and cycle time advantages for the next generation of Ariane engines.

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